Kawasaki Ninja Service Manual: Front Master Cylinder Installation

Kawasaki Ninja Service Manual / Brakes / Master Cylinder / Front Master Cylinder Installation

Apply silicone grease to the sliding surface of the brake lever pivot bolt.
Tighten: Torque - Brake Lever Pivot Bolt: 1.2 N·m (0.12 kgf·m, 11 in·lb) Brake Lever Pivot Bolt Nut: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Assemble the reservoir [A] and the bracket [B] as shown in the figure.

Damper [C] Collar [D] Bolt [E] Nut [F]
Install the front brake light switch.
Tighten: Torque - Front Brake Light Switch Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb)

Front Master Cylinder Installation

Install the master cylinder clamp [A] so that the arrow mark [B] faces upward.

Front Master Cylinder Installation

Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar.
Tighten the upper clamp bolt first, and then the lower clamp bolt.

Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

Front Master Cylinder Installation

Connect the front brake light switch connector [A] as shown in the figure.
Replace the washers that are on each side of the hose fitting with new ones.

Front Master Cylinder Installation

Install the brake hose [A].

Touch the brake hose to the stopper [B] of the front master cylinder.

Tighten: Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

Front Master Cylinder Installation

Bleed the brake line (see Brake Line Bleeding).
Check the brake for good braking power, no brake drag, and no fluid leakage.

Front Master Cylinder Removal

Remove the reservoir mounting bolt and nut [A]. Unscrew the banjo bolt [A] and disconnect the brake hose from the master cylinder (see Brake Hose and Pipe Replacement in the Periodic ...

Rear Master Cylinder Removal

Unscrew the brake hose banjo bolt [A] and remove the brake hose (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). Remove: Rear Master Cylinder Mounting Bolts [B] ...

Other materials:

Balance Weight Installation
Check if the weight portion has any play on the blade [A] and clip [B]. If it does, discard it. WARNINGUnbalanced wheels can create an unsafe riding condition. If the balance weight has any play on the rib of the rim, the blade and/or clip have been stretched. Replace th ...

ZX1000JB/KB Models
1. Run the fuse box 2 lead in front of the rib for the fuse box 2. 2. Seat Lock Cable 3. Hook the licence plate light lead and the left turn signal light lead on the projection of the tool kit case. 4. Rib for Fuse Box 2 5. Run the starter relay lead in back of the rib for the fuse box 2 ...

Brake Disc Warp Inspection
Raise the wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 For front disc inspection, turn the handlebar fully to one side. Set up a dial gauge against the disc [A] as shown in the figure and measure disc runout, while turning [B] the ...